Large optical fiber array assembly and method

• US 6,470,123 B1
• Filed: 04/24/2001
• Issued: 10/22/2002
• Est. Priority Date: 07/18/2000
• Status: Expired due to Term

• Current Assignee: Fiberguide Industries, Inc. (KOCH Industries Incorporated)
• Original Assignee: Fiberguide Industries, Inc. (KOCH Industries Incorporated)
• Inventors: Rich, Theodore C., Sherman, Jonathan, Camlibel, Irfan, Rich, Ernest J.
• Primary Examiner(s): Ullah, Akm E.
• Assistant Examiner(s): CONNELLY CUSHWA, MICHELLE R
• Application Number:
  US09/841,686
• Time in Patent Office: 546 Days
• Field of Search: 385/52, 385/88-94, 385/115, 385/135-139
• US Class Current: 385/115
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3644 the coupling means being through-holes or wall apertures
• CPC Class Codes: G02B 6/3664 2D cross sectional arrangements of the fibres
• CPC Class Codes: G02B 6/3672 with fibres arranged in a regular matrix array
• CPC Class Codes: G02B 6/3676 Stacked arrangement
• CPC Class Codes: G02B 6/3692 with surface micromachining involving etching, e.g. wet or dry etching steps surface micromachining involving subtractive techniques B81C1/00055
• CPC Class Codes: G02B 6/3835 using discs, bushings or the like
• CPC Class Codes: G02B 6/3837 forwarding or threading methods of light guides into apertures of ferrule centering means
• CPC Class Codes: G02B 6/3885 Multicore or multichannel optical connectors, i.e. one single ferrule containing more than one fibre, e.g. ribbon type optical ribbon cable G02B6/4403, G02B6/448
• CPC Class Codes: G02B 6/4202 for coupling an active element with fibres without intermediate optical elements, e.g. fibres with plane ends, fibres with shaped ends, bundles
• CPC Class Codes: G02B 6/4292 the light guide being disconnectable from the opto-electronic element, e.g. mutually self aligning arrangements

Abstract

A high density optical fiber array assembly and assembly method includes a housing securing a front array mask etched with extreme precision to define openings arranged in a predetermined pattern. A series of guide plates form a series of fiber guide channels that align with the mask openings, which plates are stacked within the housing so that the bottom of one acts as a cover for the channels of another. Fibers can be tool inserted along the channels as one group, such as a row of fibers, or manually inserted and advanced sequentially. Alternately, the mask and guide plate stack are mounted to and within a mounting block and the mounting block assembly inserted into the assembly housing substantially all remaining voids in the housing are filled with bonding material.

Claims

1. A method of assembling an optical fiber array assembly including

providing an array mask with a plurality of openings extending between a rear face and forward face and arranged in a predetermined hole pattern including at least three openings,

providing at least first and second guide plates, each guide plate comprising at least three guide channels formed in one surface thereof, and said second guide plate being contiguous to said first guide plate to close the respective guide channels of said first guide plate,

securing said mask and said guide plates in fixed positions relative to each other,

before or after the above steps, removing any jackets or buffer layers from distal forward portions of at least three fibers to expose the cladding layers thereof,

advancing said forward portions of said fibers simultaneously or sequentially through said channels for guiding the fibers and translating them into at least three array mask openings, and

securing said fibers in said channels and said array mask openings, and wherein

said providing at least first and second guide plates includes providing Y guide plates, each guide plate including a set of X channels, where X equals or does not equal Y, and wherein

said array mask includes X rows of openings and Y columns of openings

said array mask comprises etchable material and said method further comprising etching said X and Y openings in said array mask, and

after said removing step, shaping the distal tip of each said fibers into a substantial cone, and forming said array mask openings as truncated cones with the larger diameter end located substantially at the forward array mask face.

2. A method according to claim 1 further comprising forming the rear portion of each array mask opening as a rear truncated cone with the larger diameter end located substantively at the rear array mask face.

4. A method according to claim 1, 2, or 3 further comprising

applying liquid epoxy material to said fiber forward portions prior to or during advancing of said fiber forward portions through said channels.

5. A method according to claim 1, 2, or 3 wherein

said securing step, at least in part, includes wetting said fiber forward portions with liquid epoxy prior to or during advancing of said fiber forward portions through said channel set,

and setting said epoxy to bond the fiber forward portions to said channels and said array mask.

6. A method according to claim 1, 2, or 3 wherein

said at least three fiber forward portions are substantially simultaneously advanced through said channels.

7. A method according to claim 6 further including

inserting longitudinally said at least three fiber forward portions substantially simultaneously into said channels.

8. A method according to claim 7 wherein

inserting includes releasably securing the jacketed portions of said at least three fibers together,

providing a guide tool with at least three tool channels for guiding the forward fiber portions and aligning said tool channels with the aft portions of said guide plate at least three channels,

applying forward translation force to the secured jacketed portions to advance said forward fiber portions through said tool channels, into said guide plate channels, until fiber tips extend through said array mask openings.

9. A method according to claim 1, 2, or 3 wherein

providing said Y guide plates includes stacking said Y guide plates.

10. A method according to claim 9 wherein

providing a topmost cover plate to cover the topmost guide plate channels.

11. A method according to claim 1, 2, or 3 wherein

said first mentioned securing step includes securing said stacked Y guide plates in a predetermined fixed position within and relative to a mounting block and securing a support mask to the forward end of the mounting block in a second predetermined fixed position relative to the array mask to provide longitudinal support to the array mask when the front surface of the array mask is ground or polished.

12. A method according to claim 1, 2, or 3 wherein

said first mentioned securing step further includes securing a guide plate housing about said Y guide plates and securing said guide plate housing within said mounting block at a predetermined position.

13. A method according to claim 12 wherein

said method further comprising providing an assembly housing defining a longitudinal chamber,

securing the mounting block within the housing walls defining the chamber such that said forward face of said array mask is substantially at the forward end of the chamber for alignment with a mating array of optical fiber ends.

14. A method according to claim 1, 2, or 3 wherein

said first mentioned guiding said fibers includes guiding the distal forward portion of each fiber directly from the respective guide plate channel into the respective array mask opening.

15. A method according to claim 1, 2, or 3 wherein

said first mentioned guiding said fibers includes guiding the distal forward portion of each fiber from the respective guide plate channel into and through a guide mask opening hen into the respective array mask opening.

16. A method according to claim 1, 2, or 3 wherein

said first mentioned securing step includes securing said stacked Y guide plates in a predetermined fixed position within and relative to an assembly housing and securing a guide mask to the forward end of the assembly housing in a second predetermined fixed position relative to the array mask.

17. A method according to claim 16 wherein

said assembly housing defines a longitudinal chamber,

securing said stacked Y guide plates within the assembly housing walls defining the chamber such that said forward face of said array mask is substantially at the forward end of the chamber for alignment with a mating array of optical fiber ends.

3. A method of assembling an optical fiber array assembly including

providing an array mask with a plurality of openings extending between a rear face and forward face and arranged in a predetermined hole pattern including at least three openings,

providing at least first and second guide plates, each guide plate comprising at least three guide channels formed in one surface thereof, and said second guide plate being contiguous to said first guide plate to close the respective guide channels of said first guide plate,

securing said mask and said guide plates in fixed positions relative to each other,

before or after the above steps, removing any jackets or buffer layers from distal forward portions of at least three fibers to expose the cladding layers thereof,

advancing said forward portions of said fibers simultaneously or sequentially through said channels for guiding the fibers and translating them into at least three array mask openings, and

securing said fibers in said channel set and said array mask openings, and wherein

said providing at least first and second guide plates includes providing Y guide plates, each guide plate including a set of X channels, where X equals or does not equal Y, and wherein

said array mask includes X rows of openings and Y columns of openings,

said array mask comprises etchable material and said method further comprising etching said x and Y openings in said array mask,

after said removing step, shaping the distal tip of each said fibers into a substantial cone, and

forming said array mask openings as truncated cones with the larger diameter end located substantially at the rear face of the array mask.

18. An optical fiber array comprising a housing,

a front mask coupled to said housing and having a plurality of spaced front mask openings,

a plurality of guide plates secured at least partially within and to said housing, each guide plate having a set of guide channels aligned with a set of front mask openings,

a set of optical fibers extending along each corresponding set of guide channels and having distal ends extending through a respective set of front mask openings, bonding means securing said fibers distal ends to said mask openings,

each of said guide plates contacting at least one other guide plate to close the guide channels of such other guide plate,

a mounting block having a forward surface,

said guide plates having forward ends positioned within the transverse profile of said mounting block,

said front mask being secured substantially adjacent said mounting block forward surface, and

said mounting block being secured within said housing,

a support mask for providing fore and aft structural support to said front mask during grinding or polishing of the front mask forward surface or a layer of material thereon, and

said support mask being secured between the rear surface of said front mask and the mounting block front surface.

19. An optical fiber array according to claim 18 further comprising

said support mask being secured behind the rear surface of said front mask.

20. An optical fiber array according to claim 19 wherein

the fiber openings in the support mask are flared with the widest opening portion at the rear surface of the support mask.

21. An optical fiber array according to claim 18 wherein

at least two guide plates comprise forward facing alignment pins and said front mask comprises at least the same number of alignment holes for receiving said alignment pins to assure proper alignment of said guide plate channels with respective front mask openings.

22. An optical fiber array as according to claim 18 wherein

said housing houses said mounting block and all of said guide plates.

23. An optical fiber array according to claim 22 wherein

bonding material fills substantially all spaces within the housing around the guide plates and fibers.